Brief History

Engine Division, koraput was established in the year 1964 to manufacture R11F2-300 Sr III engines for fitment in MiG-21FL Aircraft under licence from erstwhile USSR. In 1976 facilities were established to manufacture R25 engines for fitment in MiG-21BIS aircraft. Subsequently Division also manufactured R29b and RD33 Engines under licence from Russia.

Since the early 1970, overhauling facilities were established in the Division and Division has been overhauling Aero Engines of Various types i.e. R11, R25, R29 and RD33 which power MiG-21FL, MiG-21BIS, MiG-27 and MiG-29 respectively.

Over last five decades Division has manufactured more than 1300 engines and overhauled more than 7000 Aero Engines of various types with an aim to ensure maximum aircrafts flying.

R25/R29/RD33 Overhaul Projects

The Division follows the 'Group Technology' with the Engine parts being dismantled, viewed and loaded to different work centers for ROH activities. Regular review of progress through latest IT enabled systems ensures timely completion of assemblies and sub-assemblies of the engines. The stripped components are subject to stringent quality checks using modern technology like CMM, NDT and other non-contact measurements. Repair and refurbishing of worn-out parts and sub-assemblies are undertaken by skilled workmen. Division is also manufacturing most of the components in-house, which are required during overhaul. Repairs and Refurbishing Processes include welding, hard alloy coatings, vibro-tumbling, micro-shot peening, ultrasonic strain hardening, nickel alloy powder coating and a large number of protective coatings. Assemblies, sub-assemblies and Engine accessories undergo rigorous functional tests on various Hydraulic, Fuel and Electrical Rigs. Quality control checks are carried out using various NDT methods, like X-ray, Magna-flux, Dye-penetrant check and ultrasonic inspection besides other conventional techniques. Overhaul of accessories is carried out in environmentally controlled rooms. Every manufactured / overhauled Engine undergoes rigorous tests on Engine test beds that simulate all flight conditions. The preliminary and final acceptance test, hot test, endurance test and gas dynamic stability tests are conducted through computerized controls. Electronically assisted throttle, digital and analog read-outs help get real-time simultaneous data and engine parameters during Engine testing.

TBO & TTL of different Engines are given below:

Project

TBO

TTL

R25

400 Hrs

1200 Hrs

R29

550 Hrs

1500 Hrs

RD33

300 Hrs

1000 Hrs

Rotables
In addition to Engine IAF gives us additional task to overhaul Rotables. There are more than 40 types of Rotables which are being overhauled in-house. All these Rotables undergo vigorous Quality checks and testing procedure before being released to bases for exploitation.

Supply of Spares and other major units
The Division manufactures and supplies the entire range of spares required for first and second-line servicing of engines at the IAF bases and base repair depots.

Site Repair
The Division undertakes site repair of Engines at the IAF bases by deputing site repair teams regularly.

Defect Investigation/Failure Analysis
The Engines / Aggregates which are received due to premature withdrawal from the units are studied and the causes for defects/failures are investigated. After proper analysis and deliberation, corrective action is taken to minimize the recurrence of defects in future.

Workshops
The Division conducts workshops regularly to the customers at Koraput in specialized areas for better understanding and utilization of the products.

Positioning of Service Engineers
The Division has posted Service Engineers at various IAF bases to closely liaise and assess the requirement of the customers. Based on the feed-back received from these Service Engineers, the Division renders adequate support for fully utilizing the products.

Certificates

Quality Systems Certificate 9100C received

Environment System Certificate 14001:2004

NADCAP certificate for Central laboratory

Engine Division - Koraput has the following high tech facilities

Large capacity lathes for tip tuning and tip grinding of rotor assemblies.

The Engine Division at Koraput, a unit of HAL's vast network, has the unique distinction of being one amongst the few Aero Engine manufacturers in the world.

The spectrum of manufacturing facilities extends literally from the production of nuts and bolts to discs, shafts, blades, forgings and castings - all that are required to make an Aero Engine right from the Raw materials.

This spectrum is further enlarged to include overhaul of Aero Engines for the MiG family and supply of spares required during service

R25 engine

This is a Twin Spool, Axial Flow, Turbojet Engine fitted with After burner and a variable area Jet nozzle. It powers the MiG-21 BiS multi-role Fighter Aircraft. The Engine has provision for an emergency After-burner thrust boost, which can be selected below 4.5 KM altitude.

Quality control checks are carried out using various NDT methods, like X-ray, Magna-flux, Dye-penetrant check and ultrasonic inspection besides other conventional techniques. Overhaul of accessories is carried out in environmentally controlled rooms. All the accessories after overhaul are subjected to stringent tests on test rigs.